Float arm assembly and method of manufacture

Abstract

A float arm assembly and method of construction therefore has a float arm with a free end and another end arranged for operable communication with a float arm position sensor. A float is molded to the float arm to provide a unitary and rigid float arm assembly.

1 . A float assembly for use in a fuel tank, comprising: 
 a metal float arm; and    a float molded as a single piece directly onto at least a portion of the float arm so that the float is carried by the float arm.    
   
   
       2 . The assembly of  claim 1  wherein the float arm has a free end and the float extends at least in part beyond the free end.  
   
   
       3 . The assembly of  claim 1  wherein the float arm includes at least one attachment feature that retains the float on the float arm and over which the float is molded.  
   
   
       4 . The assembly of  claim 3  wherein the attachment feature includes a groove formed therein with the float extending at least partially into the groove.  
   
   
       5 . The assembly of  claim 4  wherein the float arm has a plurality of grooves formed therein with the float extending at least partially into the grooves.  
   
   
       6 . The assembly of  claim 3  wherein the attachment feature includes a bent portion of the float arm.  
   
   
       7 . The assembly of  claim 6  wherein said bent portion is located adjacent a free end of the float arm.  
   
   
       8 . The assembly of  claim 2  wherein the free end is encapsulated by the float.  
   
   
       9 . The assembly of  claim 3  wherein attachment feature includes a protrusion on the float arm.  
   
   
       10 . The assembly of  claim 9  wherein the float arm has a plurality of protrusions with a channel being defined between each pair of adjacent protrusions and said float extending within said channels.  
   
   
       11 . The assembly of  claim 10  wherein said float substantially occupies said channels.  
   
   
       12 . The assembly of  claim 3  wherein the attachment feature includes a hole formed in the float arm with the float extending at least partially into the hole.  
   
   
       13 . (canceled)  
   
   
       14 . The assembly of  claim 1  wherein the material of the float arm has a melt temperature greater than the mold temperature of the material of the float.  
   
   
       15 . (canceled)  
   
   
       16 . A method of constructing a float arm assembly for use in a fuel tank, comprising the steps of: 
 providing a float arm;    arranging the float arm in a mold cavity; and    molding a substantially solid float over at least a portion of the float arm.    
   
   
       17 . The method of  claim 16  wherein the molding step is performed by injection molding the float onto the float arm.  
   
   
       18 . The method of  claim 16  wherein the molding step is performed by blow molding the float onto the float arm.  
   
   
       19 . The method of  claim 16  including forming the float arm from a polymeric material.  
   
   
       20 . The method of  claim 19  including constructing the float arm from a material having a higher melt point than the material of the float.  
   
   
       21 . The method of  claim 19  including injection molding the float arm.  
   
   
       22 . The method of  claim 19  including extruding the float arm.  
   
   
       23 . The method of  claim 22  including forming at least one bend in the float arm after the extruding step.  
   
   
       24 . The method of  claim 16  wherein the float arm is provided having a free end and including molding the float so that at least a portion of the float extends outwardly beyond the free end.  
   
   
       25 . The method of  claim 16  including the step of forming a groove in the float arm prior to the molding step.  
   
   
       26 . The method of  claim 25  including molding the float so that at least a portion of the float extends into the groove.  
   
   
       27 . The method of  claim 16  including the step of bending the float arm prior to the molding step.  
   
   
       28 . The method of  claim 16  including the step of forming a protrusion on the float arm prior to the molding step and wherein the molding step includes molding the float over the protrusion.  
   
   
       29 . The method of  claim 28  including forming the float arm with a plurality of protrusions to define a channel between adjacent protrusions.  
   
   
       30 . The method of  claim 29  wherein the molding step includes molding the float so that at least a portion of the float extends into at least one channel.  
   
   
       31 . A float arm assembly for use in a fuel tank, comprising: 
 a float arm; and    a substantially solid float having a discontinuous passage with the float arm being received at least in part within the discontinuous passage.    
   
   
       32 . The assembly of  claim 31  wherein the discontinuous passage includes at least one bend with the float arm extending through the bend.  
   
   
       33 . The assembly of  claim 31  wherein the float arm has at least one groove and the discontinuous passage includes at least a portion of the float extending into the grooves.  
   
   
       34 . The assembly of  claim 33  wherein the float arm has a plurality of grooves and the discontinuous passage includes portions of the float extending into the grooves.  
   
   
       35 . The assembly of  claim 31  wherein the float arm has a protrusion and the discontinuous passage includes at least a portion of the float disposed around the protrusion.  
   
   
       36 . The assembly of  claim 35  wherein the float arm has a plurality of protrusions and the discontinuous passage includes portions of the float arm disposed around the protrusions.  
   
   
       37 . The assembly of  claim 31  wherein the float arm has a hole and the discontinuous passage includes a portion of the float extending into the hole.  
   
   
       38 . The assembly of  claim 31  wherein the float arm has a free end and the discontinuous passage is constructed as an enclosed cavity substantially encapsulating the free end.  
   
   
       39 . The method of  claim 16  including the step of forming a hole on the float arm prior to the molding step and wherein the molding step includes molding the float over and at least partially into the hole.